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“Using the PI System, we were able to reduce our PM replacement costs resulting in an annual savings of $700 k.”
Dale Rhodes
Process Control Specialist
Millennium: How can we improve management of rotating equipment availability by predicting equipment life based on operating time and experiences using existing systems?
Customer Business Challenge Solution Results / Benefits
• Improve Management of rotating equipment availability.
Improve management of rotating equipment availability by predicting equipment life based on operating time and experiences?
• Requirements– Leverage existing systems– Make it secure– Generate notifications
• Email, text messaging (future ERP integration)– Integrate providing mechanic with needed documents and procedures
• Solution– OSISoft software
– Module Database (future AF migration)– Simplified single display and spreadsheet creation– Data can be secured using Excel SMT add-in– Links to network locations
• Module Database (aliasing and properties)• PI Totalizers (Runtimes)• PI Performance Equations (setpoint minus runtime)• VBA (User logon)• OSI DevNet EMNotify (setpoint reached)
– Source code was altered to allow tag values in the ‘subject’ and file attachments
• Reduced PM replacement cost– Annually equating to $700k, and we’re not done!
• Increased available maintenance man hours• Enabling removal of existing runtimes from the control
systems– More available memory and processing time– Disparate systems were hard to manage (Rockwell, DeltaV, RS3)– Control Systems not the place for maintenance activities
• Operators need to concentrate on running the plant